Tire with double half-carcasses and adapted crown zone

ABSTRACT

A tire comprising at least one reinforcement structure of carcass type anchored on each side of the tire in a bead, a crown reinforcement, sidewalls meeting up radially towards the outside with a tread, the carcass-type reinforcement structure extending circumferentially from the bead towards said sidewall and being discontinuous over at least a portion of the crown of the tire, said crown reinforcement comprising on the one hand at least one primary reinforcement structure covering substantially the entire width of the crown and on the other hand at least one series of circumferential reinforcements also covering substantially the entire width of the crown, said series of circumferential reinforcements comprising a portion of lateral circumferential reinforcements disposed radially to the outside relative to said primary reinforcement structures and a portion of median circumferential reinforcements disposed radially to the inside relative to said primary reinforcement structures.

The present application is a continuation of International Application Serial No. PCT/EP02/12019 filed on Oct. 28, 2002, and which claims priority under 35 U.S.C. §119 to Patent Application Serial No. 01/14089 filed in France on Oct. 29, 2001, the entire content of which is hereby incorporated by reference.

The present invention relates to tires. More particularly, it relates to the arrangement and configuration of the reinforcement structure in the crown zone of the tire.

Tire reinforcements currently comprise one or more plies known conventionally as “carcass plies”, “crown plies”, etc. This way of naming the reinforcements results from the manufacturing process, consisting of producing a series of semi-finished products in the form of plies, provided with frequently longitudinal cord reinforcements (destined to become radial after assembly), which are then assembled to build a tire. The plies are made flat, with large dimensions, and are then cut as a function of the dimensions of a given product. The plies are also assembled substantially flat in a first phase. The blank thus produced is then shaped into the toroidal profile typical of tires. The semi-finished products known as “finishing products” are then applied to the blank, in order to obtain a product which is ready for vulcanisation.

This same conventional process involves the use of a bead wire, used to effect anchoring or retention of the carcass ply in the bottom zone of the sidewall. Thus, conventionally, a portion of ply is turned up about a bead wire disposed in the tire bead. The carcass ply is thereby anchored in the bead.

The widespread use in the industry of this conventional process, despite numerous variants in the manner of producing plies and assemblies, has led the person skilled in the art to use a vocabulary modelled on the process; hence the generally accepted terminology, consisting in particular of the terms “plies”, “carcass”, “bead wire”, “shaping” used to designate transformation from a flat profile to a toroidal profile etc.

However, tires now exist which do not strictly speaking comprise “plies” or “bead wires” which fit the above definitions. For example, document EP 0 582 196 describes tires manufactured without the aid of semi-finished products in the form of plies. For example, the cords of the various reinforcement structures are applied directly to the adjacent layers of rubber mixes, the whole being applied in successive layers to a toroidal core, the shape of which allows the direct obtainment of a profile resembling the final profile of the tire being manufactured. Thus, in this case there are no longer “semi-finished products”, or “plies” or “bead wires”. The basic products such as the rubber mixes and the reinforcements in the form of filaments are applied directly to the core. Since this core is toroidal in shape, the blank no longer has to be shaped in order to be transformed from a flat profile to a profile in the form of a torus.

Furthermore, the tires described in this document do not have the traditional carcass ply turn-up about a bead wire. This type of anchoring is replaced by an arrangement in which circumferential filaments are disposed adjacent said sidewall reinforcing structure, the whole being immersed in an anchoring or bonding rubber mix.

Assembling processes using a toroidal core also exist which use semi-finished products specially adapted for rapid, effective and simple laying on a central core. Finally, it is also possible to use a composite comprising certain semi-finished products to achieve certain architectural aspects (such as plies, bead wires, etc), while others are achieved by the direct application of mixes and/or reinforcements in the form of filaments.

In the present document, so as to take account of recent technological developments both in the field of manufacture and in the design of products, the conventional terms such as “plies”, “bead wires” etc are advantageously replaced by neutral terms or terms which are independent of the type of process used. Thus, the term “reinforcement of carcass type” or “sidewall reinforcement” may be used to denote the reinforcement cords of a carcass ply in the conventional process and the corresponding cords, generally applied at the level of the sidewalls, of a tire produced according to a process not using semi-finished products. The term “anchoring zone”, for its part, may denote both the conventional carcass ply turn-up about a bead wire of the conventional process and the assembly formed by the circumferential filaments, the rubber mix and the adjacent sidewall reinforcement portions of a bottom zone produced using a process involving application on a toroidal core.

Whatever the process used, the reinforcements of carcass type, or sidewall reinforcements, generally extend from one bead to the other via the crown. They thus contribute in part to the reinforcement of the crown zone. Other elements, such as reinforcement cords arranged in a single layer or in multiple layers (such as for example cords at 30 degrees relative to the circumferential direction), contribute to establishing a crown structure which is sufficiently rigid, hard-wearing etc to fulfil the anticipated conditions of use.

Depending on type of use, a larger or smaller number of reinforcement elements are required at the level of the crown. These elements sometimes occupy a large space and/or constitute a large mass. The thickness of the crown zone thus frequently depends on the type of reinforcements which this zone has to accommodate. Although it is often desirable to limit the thickness and/or mass of said zone, there is often only limited room for manoeuvre. In effect, the “weight/bulk/mechanical properties” compromise frequently obliges designers to lower their sights with regard to the first two aspects in order to satisfy the third. One way or another, the achievement of a perfect balance between each of the facets of this compromise usually requires numerous tests sometimes involving numerous modifications before a suitable balance is obtained.

The present invention is directed at optimising this compromise for certain types of tires.

Thus, the invention provides a tire comprising at least one reinforcement structure of carcass type anchored on each side of the tire in a bead whose base is designed to be mounted on a rim seat, a crown reinforcement, each bead being extended radially towards the outside by a sidewall, the sidewalls meeting up radially towards the outside with a tread, the reinforcement structure of carcass type extending circumferentially from the bead towards said sidewall and being discontinuous over at least a portion of the crown of the tire, said crown reinforcement comprising on the one hand at least one primary reinforcement structure covering substantially the entire width of the crown and on the other hand at least one series of circumferential reinforcements also covering substantially the entire width of the crown, said series of circumferential reinforcements comprising a portion of lateral circumferential reinforcements disposed radially to the outside relative to said primary reinforcement structures and a portion of median circumferential reinforcements disposed radially to the inside relative to said primary reinforcement structures.

Such an architecture provides numerous advantages. For example, the crown region may be made thinner and/or lighter. The crown zone without reinforcement structure allows economies of material. It also allows the meridian and circumferential rigidity of the tire to be optimised.

Otherwise, the substantially central zone of the crown, freed of the presence of the carcass-type structures, may advantageously be used for the incorporation of other types of architectural or structural element, such as for example reinforcements, cables, cords, inserts, rubber zones exhibiting different mechanical characteristics etc.

According to one advantageous example of embodiment of the invention, said median circumferential reinforcement portion is disposed substantially between the end portions of the carcass-type reinforcement structures.

This original positioning of the circumferential reinforcements allows the freeing-up, for example, of a substantial space in the crown zone.

The special positioning of the median circumferential reinforcements, preferably beneath the circumferential neutral axis, makes it possible, in the area of contact with the ground, for flattening of the crown zone to subject the reinforcements to tensile stress instead of compressive stress in their conventional position. Since the mechanical characteristics of the reinforcements are generally superior under extension (for example for reinforcements of textile type), greater rigidity of the crown block may thus be obtained.

According to another advantageous example of the invention, the tire also comprises a secondary reinforcement structure disposed radially towards the outside relative to the primary reinforcement structure, substantially between the lateral reinforcement portions.

The invention provides advantageous mechanical properties due to the presence of this structure with a crown of optimum thickness.

According to another advantageous example of embodiment of the invention, the primary and/or secondary reinforcement structure comprises cord elements generally arranged at an angle other than zero degrees (such as, for example, 90 degrees) relative to the circumferential direction. This may be a fixed angle or vary according to the axial position. This angle may pass through zero degrees at a given point, but the main portion of its course preferably exhibits angles other than this value.

According to another advantageous example of the invention, the tire also comprises a peripheral rubber mix zone disposed radially towards the outside relative to the primary reinforcement structure, substantially between the lateral reinforcement portions. The presence of such a zone may achieve various advantages, such as for example: protection against external attack, improved endurance and/or comfort, reduced rolling resistance and/or noise, increased rigidity etc.

According to another advantageous example of embodiment of the invention, the tire also comprises at least one substantially median extra-deep hollow.

Extra-deep means that the depth is advantageously greater than for a traditional tire. For example, a groove may be extended radially so as to be substantially radially aligned with the lateral circumferential reinforcements, or may even be extended radially to the inside of these reinforcements. This greater depth provides flexibility of action, depending on requirements and the type of tire. For example, deeper grooves may serve to accommodate/evacuate a greater amount of water, contributing to optimisation of the hydrodynamic qualities of a tire.

According to another advantageous example, the reinforcement structure of carcass type is double over at least one of the two sides of said tire. It is possible to have a double reinforcement for example solely on the outer side of the tire, for fitting on the outer side of the vehicle. The tire is then simple and cheap, while displaying excellent protection against the hazards of the road, such as impacts. It may also constitute a mode of reinforcement for the sidewall, a means of adjusting or increasing the rigidity of the sidewall, etc.

Advantageously, the tire according to the invention may be manufactured by means of a tire manufacturing process in which the various constituent elements are laid in turn directly on a core, the profile of which corresponds substantially to that of the final product, and in which laying of a first reinforcement structure on a first side of a tire and of a second reinforcement structure on a second side of said tire may be effected substantially simultaneously.

In the case of a tire manufactured by such an automated process, in which the various constituent elements are laid in turn directly on a core, whose profile corresponds substantially to that of the final product, the provision of two independent half-structures may allow manufacturing time to be optimised. Thus, for example, it is possible to use two reinforcement structure laying machines, capable of operating simultaneously during manufacture of the tire. The result thereof is therefore a considerable reduction in reinforcement structure laying time.

In the present specification, the term “cord” denotes wholly generally both monofilaments and multifilaments, or assemblies such as cables, plied yarns or indeed any equivalent type of assembly, whatever the material of these cords and whatever the treatment they have undergone, for example surface treatment or coating or presizing to promote adhesion to the rubber.

A “circumferentially oriented cord” denotes a cord oriented substantially in a single axial plane or in a plane forming an angle less than or equal to 10° with an axial plane.

As a reminder, “radially towards the top” or “radially upper” means towards the larger radii.

The “modulus of elasticity” of a rubber mix is a secant modulus of extension obtained under uniaxial extension deformation of the order of 10% at ambient temperature.

A reinforcing or reinforcement structure of carcass type is radial when its cords are arranged at 90°, but also, according to the terminology in use, at an angle close to 90°.

It is known that, in the art as it currently stands, the carcass ply or plies are turned up about a bead wire. The bead wire then performs the function of carcass anchoring, that is to say it absorbs the tension developing in the carcass cords under the effect of the inflation pressure. In the configurations described in the present application, not using a bead wire of traditional type, the function of anchoring the reinforcement structure of carcass type is likewise ensured.

It is also known that, still as in the prior art, the same bead wire additionally performs the function of clamping the bead to its rim. In the configurations described in the present application, not using a bead wire of traditional type, the clamping function is likewise ensured, in particular by the circumferential cord windings closest to the seat.

It goes without saying that the invention may be used in generally attaching other elements to the bead or to the bottom zone of the tire, as certain variants will illustrate. Likewise, in the invention multiple reinforcement structures of the same nature may be used or a different type of reinforcement structure may be attached.

All practical details are given in the following description, supplemented by FIGS. 1 to 6, in which:

FIG. 1 is a radial section essentially showing a sidewall, a bead and a crown portion of a first form of embodiment of a tire according to the invention;

FIG. 2 is a radial section essentially showing a sidewall, a bead and a crown portion of a variant of the form of embodiment of FIG. 1;

FIG. 3 is a radial section essentially showing a sidewall, a bead and a crown portion of another variant of the form of embodiment of FIG. 1;

FIG. 4 is a radial section essentially showing a sidewall, a bead and a crown portion of another form of embodiment of a tire according to the invention;

FIG. 5 is a radial section essentially showing a sidewall, a bead and a crown portion of another variant of the form of embodiment of FIG. 1;

FIGS. 6 and 7 illustrate the arrangements of the basic architectural elements of a tire according to the invention.

FIG. 1 is a sectional view of a first form of embodiment of the tire according to the invention. The bead 1 comprises an axially outer portion 2 provided and shaped in such a way as to be placed against the flange of a rim. The bead 1 ends radially towards the inside in a bead seat 4, adapted to be disposed against a rim seat. The bead likewise comprises an axially inner portion 3, extending substantially radially from the seat 4 towards the sidewall 6.

The tire also comprises a reinforcing structure 10 or carcass-type reinforcement structure provided with reinforcements advantageously configured in a substantially radial arrangement. This structure preferably comprises two portions, for example one each side of the tire, arranged for example along the sidewalls, without covering the entire crown.

The crown 40 comprises a reinforcement consisting of at least one and preferably two primary reinforcement structures (crown plies), providing this tire zone with the required protection and rigidity. In the example illustrated in FIG. 1, an inner primary reinforcement structure 42 and an outer primary reinforcement structure 43 are disposed adjacent and substantially parallel to one another. The orientation of the primary reinforcement structure cords is preferably reversed and intersecting. A space filled with suitable rubber mix is provided between the two structures in order to prevent any contact between them.

The crown reinforcement also comprises a series of circumferential reinforcements 44 disposed substantially at zero degrees and substantially parallel to one another. The transverse row formed by the reinforcements covers substantially the entire width of the crown. The reinforcements advantageously consist of substantially circumferential cords. The presence of such an arrangement may be desired in order to optimise the mechanical properties of the crown of the tire, in particular in terms of circumferential rigidity. The series of circumferential reinforcements is subdivided into two portions: a median circumferential reinforcement portion 44 and a lateral circumferential reinforcement portion 46. In the example illustrated, the cords of the portion 44 are arranged radially to the inside relative to the inner structure 42. In order to gain maximum benefit from the space freed up by the omission of the central (or crown) portion of the reinforcement structure 10, the preferred radial position of the circumferential reinforcements 44 is such that they are disposed substantially between the ends 14 of the lateral reinforcements 10. The cords of the portion 46 are disposed at the edge of the crown, on the one hand radially outside the primary reinforcement structure and on the other hand axially substantially outside the median circumferential reinforcement portion 44. According to an advantageous variant of the invention, the median and lateral circumferential reinforcements overlap over a portion of their axial course. A tread 41 is provided in the radially outer portion of the crown.

In the example illustrated in FIG. 1, a peripheral rubber mix zone 48 is disposed radially to the outside of the primary reinforcement structure. Widthwise, it may occupy a portion or indeed all of the space available between the lateral circumferential reinforcements 46. The fact that the median circumferential reinforcements are disposed radially inside the primary reinforcement structure allows a space to be formed in the radially outer zone of the crown, under the tread. This zone is used in this embodiment to accommodate a special rubber mix whose characteristics are selected as a function of the type of tire. Some non-limiting examples follow of types of mixes:

-   -   a shock-absorbing mix: this mix is capable of having a positive         effect on comfort, in particular on body noise and/or humming;     -   a mix with a high modulus of elasticity: such a mix is capable         of having a favourable effect on slip behaviour;     -   a low hysteresis mix: such a mix is capable of reducing the         hysteresis losses at the level of the crown with a favourable         effect on the level of rolling resistance.

In the example illustrated in FIG. 2, a secondary reinforcement structure 49 is disposed radially to the outside of the primary reinforcement structure. Widthwise, it may occupy a portion or indeed all of the space available between the lateral circumferential reinforcements 46. The fact that the median circumferential reinforcements are disposed radially inside the primary reinforcement structure allows a space to be formed in the radially outer zone of the crown, under the tread. This zone is used in this embodiment to accommodate a secondary reinforcement structure advantageously comprising special cord reinforcement elements whose characteristics are selected as a function of the type of tire, for example, reinforcement elements oriented substantially at 90° relative to the circumferential direction, in particular metal reinforcements with an elevated compression rigidity, in order to increase the rigidity of the crown zone.

In the example illustrated in FIG. 3, the free space in the outer zone of the crown is used for arranging tread pattern elements provided with hollows 47, such as for example grooves, the depth of which is advantageously greater than for a traditional tire, as illustrated in dotted lines for the purpose of comparison with the comparison depth ΔP. This greater depth provides flexibility of action, depending on requirements and the type of tire. For example, deeper grooves may serve to accommodate/evacuate a greater amount of water, contributing to optimisation of the hydrodynamic qualities of a tire. It is also possible to design a tire of elevated service life, due to the tread pattern elements which may suffer more pronounced wear.

According to an advantageous variant illustrated in FIG. 4, at least one of the two portions comprises a reinforcement structure provided with double reinforcements, namely an inner reinforcement 11 and an outer reinforcement 12, in accordance with their respective position at the level of the meridian profile of the tire. The reinforcements are arranged in adjacent manner and substantially parallel to one another and are spaced or separated from one another by a separating layer of rubber mix 15.

In the radially outer portion of the sidewall or in the region of the crown 40, the inner 11 and outer 12 reinforcements each comprise an end portion, respectively 13 and 14. These end portions are advantageously staggered. Thus, in the example illustrated, the axial positions of the end portion of the inner reinforcement 13 and the end portion of the outer reinforcement 14 are not the same: the end portion of the inner reinforcement 13 is axially further towards the outside than the end portion of the outer reinforcement 14.

FIG. 5 illustrates a variant comprising a traditional bottom zone with a turn-up about a bead wire. Such a bottom zone may also be used for one or other embodiment of the present invention.

FIGS. 6 and 7 illustrate more particularly an advantageous arrangement of the cords of the reinforcement structure 10. FIG. 6 illustrates a portion of the course of a structure comprising a single cord arranged in zigzag fashion to form a series of substantially parallel cord sections connected at the bottom and top by bottom loops 16 and top loops 17. The second structure 12 (not illustrated in this sectional view) is advantageously similarly configured. FIG. 6 additionally illustrates the bottom zone interface between the structure 10 and the cords 21. FIG. 7 illustrates the lower layers of a tire portion. The advantageous orientation of a monofilament structure as described above, for example the inner reinforcement 11, is illustrated here over a portion of a tire, in such a way as to show the interaction between the various architectural elements present, in particular the crown plies 42 and 43 and the circumferential cords 21. The radially upper portion of the arrangement on the opposite side is also partially visible in this same Figure.

In order to ensure perfect anchoring of the reinforcement structure, a composite, stratified bead is preferably produced. Inside the bead 1, circumferentially oriented cords are arranged between the cord rows of the reinforcement structure. These cords are disposed in a pile as in the Figures, or in several adjacent piles, or in bundles, or in any sensible arrangement, depending on the type of tire and/or the characteristics sought.

Circumferential cords 21, preferably arranged in the form of piles, form an arrangement of anchoring cords 20, provided in each of the beads. These cords are preferably of metal, and optionally brass coated. In each pile, the cords are advantageously substantially concentric and superposed.

The radially inner end portions of the reinforcement structure 10 cooperate with the beads. In this way, these portions are anchored in said beads in such a way as to ensure the integrity of the tire. To assist in this anchoring, the space between the circumferential cords and the reinforcement structure is occupied by a bonding rubber mix. It is also possible to use a plurality of mixes having different characteristics, delimiting a plurality of zones, the combinations of mixes and resultant arrangements being virtually unlimited. However, it is advantageous to provide for the presence of a mix with a high modulus of elasticity in the intersection zone between the cord arrangement and the reinforcement structure. By way of non-limiting example, the modulus of elasticity of such a mix may reach or even exceed 15 to 20 Mpa, and even in some cases reach or indeed exceed 40 Mpa.

The cord arrangements may be arranged and manufactured in various ways. For example, a pile may advantageously consist of a single cord wound (substantially at zero degrees) in a spiral of several turns, preferably from the smallest diameter to the largest diameter. A pile may also consist of a plurality of concentric cords positioned one inside the other, so as to superpose rings of progressively increasing diameter. It is not necessary to add a rubber mix to ensure impregnation of the reinforcement cord, or of the circumferential cord windings.

In order to position the reinforcement cords as precisely as possible, it is highly advantageous to build the tire on a rigid support, for example a rigid core determining the shape of the inner cavity thereof. All the constituents of the tire are applied to this core, in the order required by the final architecture, being arranged directly in their final location without the profile of the tire having to be turned over or folded during building. This building may use the devices described for example in EP 0 580 055, and French patent application 00/01394, for laying carcass reinforcement cords and in document EP 0 264 600 for laying the rubber products. The tire may be moulded and vulcanised as set forth in patent U.S. Pat. No. 4,895,692. 

1. A tire comprising at least one reinforcement structure of carcass type anchored on each side of the tire in a bead whose base is designed to be mounted on a rim seat, a crown reinforcement, each bead being extended radially towards the outside by a sidewall, the sidewalls meeting up radially towards the outside with a tread, the carcass-type reinforcement structure extending circumferentially from the bead towards said sidewall and being discontinuous over at least a portion of the crown of the tire, said crown reinforcement comprising on the one hand at least one primary reinforcement structure covering substantially the entire width of the crown and on the other hand at least one series of circumferential reinforcements also covering substantially the entire width of the crown, said series of circumferential reinforcements comprising a portion of lateral circumferential reinforcements disposed radially to the outside relative to said primary reinforcement structures and a portion of median circumferential reinforcements disposed radially to the inside relative to said primary reinforcement structures.
 2. The tire of claim 1, in which said median circumferential reinforcement portion is disposed substantially between the end portions of the carcass-type reinforcement structures.
 3. The tire of claim 1, also comprising a secondary reinforcement structure disposed radially towards the outside relative to the primary reinforcement structure, substantially between the lateral reinforcement portions.
 4. The tire of claim 1, in which the primary and/or secondary reinforcement structure comprises cord elements generally arranged at an angle other than zero degrees relative to the circumferential direction.
 5. The tire of claim 1, also comprising a peripheral rubber mix zone disposed radially towards the outside relative to the primary reinforcement structure, substantially between the lateral reinforcement portions.
 6. The tire of claim 1, also comprising at least one substantially median extra-deep hollow.
 7. The tire of claim 1, in which the reinforcement structure of carcass type is double over at least one of the two sides of said tire. 